System for the Production of a Metal Component by Continuous Casting

ABSTRACT

The present invention provides a system for the production of an iron component by continuous casting including a mold adapted to receive liquid metal through an inlet channel defined in the match mold, which is disposed at least partially within the mold.

FIELD OF THE INVENTION

The present invention relates to continuous casting systems for the manufacture of iron components, in particular metal bars with hollow profiles.

FUNDAMENTALS OF THE INVENTION

Metal bars are widely used in various areas of industry in various applications. Such bars may comprise a wide variety of formats, which vary according to the specific application of each case, in particular when produced by a continuous casting process. This wide range of applications is due to the fact that the process of continuous casting makes it possible to manufacture bars with varying dimensions, satisfying the needs of various areas of the industry.

For the manufacture of such bars, cast iron molding devices are generally used which receive cast iron at one end, mold and cool the cast iron, partially solidifying it, and release a cast iron segment into a second end. The described process is continuous, so as to form a continuous bar through this process. As already described, the profile of the mold can be varied so as to adapt to each application. Continuous casting processes, which are used for making compact metal bars, are widely known to those skilled in the art, and are widely described in specialized technical literature.

In addition, it will be appreciated that the current state of the art also already comprises continuous casting processes capable of making hollow or hollow metal bars, i.e., non-compact metal bars.

In this regard, the patent document U.S. Pat. No. 4,775,000 describes a continuous casting process of tubular parts by incremental reservoir of centrifugal material, wherein casting metal is centrifugally deposited adjacent to the outlet of the shape. For this purpose, a mold cooled by a fluid is provided, which causes the outermost region of the casting metal (which is in contact with the mold) to solidify, forming the cylindrical part. In addition, bearings positioned in a region subsequent to the exit of the mold are provided. These bearings are in contact with the part produced and exert force, so that it exits the mold.

Patent document WO 2015/089959, on the other hand, discloses a cast iron hollow duct and a method for making such a duct. To this end, use is made of a melting furnace connected to a rotating magnetic field generator and a crystallizer, wherein casting metal flows and is rotated in the crystallizer by the magnetic field. The crystallizer rapidly cools the temperature of the casting metal, making it solid and forming the duct. After leaving the mold, the formed duct is drawn by traction rollers, which causes the duct segments in formation in the crystallizer to, also, be rationed.

In order for the metal tube to be generated by continuous casting, it is necessary for the graphite mandrel to have at least a part of its base in contact with the indirect cooling. This allows the graphite to maintain its integrity and does not lose its mechanical properties. This continuous casting process allows the bars to have any length desired by the final customer, obviously limited to the logistics capacity.

It is from this scenario that the present invention arises.

OBJECTIVES OF THE INVENTION

The present invention aims to provide a system for the production of a hollow iron (hollow bar) component by skilled continuous casting whose internal surface finish is similar to the outer surface finish. This finish is only possible thanks to the continuous casting system coupled with the shape of the graphite mandrel which, through indirect cooling, maintains its mechanical properties allowing the tube to be extracted by traction without the mandrel breaking.

SUMMARY OF THE INVENTION

In order to achieve the above-described objects, the present invention provides a system for the production of a metal component by continuous casting, which comprises at least one mold integrated by at least one molding chamber and at least one cooling channel external to the molding chamber.

In general terms, according to the invention in question, said molding chamber comprises at least one outlet port of metal in solid state and said cooling channel comprises at least one inlet port of cooling fluid and at least one outlet port of cooling fluid.

Also provided is a match mold which, disposed at least partly inside the molding chamber of the mold, comprises a tubular body provided with at least one interface end and at least one inlet port of metal in liquid state, that the overall molding format is defined by the circumferential gap existing between the molding chamber and the match mold.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description set forth below makes reference to the attached figures and their respective reference numerals.

FIG. 1 schematically illustrates a system for producing an iron component by continuous casting according to an optional configuration of the present invention;

FIG. 2 shows an optional mold configuration that can be applied to the system of the invention;

FIG. 3 shows a partial cross-sectional view of the optional mold configuration of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

First of all, it will be appreciated that the following description will depart from a preferred embodiment of the invention. As will be apparent to a person skilled in the art, however, the invention is not limited to that particular embodiment.

FIG. 1 schematically illustrates a system for producing an iron component by continuous casting according to an optional configuration of the present invention. Such a system is used to carry out a process of producing an iron component by continuous casting which, in its simplest configuration, comprises the steps of inserting liquid metal into a mold through an inlet end, solidifying the liquid metal inside the mold and at least partially removing a segment of solidified metal component through an outlet end of the mold, wherein the removal is effected through traction. In addition, for the process to enable the continuous production of a metal component, the above steps are repeated sequentially, so that when a component segment is solidified and partially removed, a new amount of liquid metal is inserted into the mold. As the new amount of liquid metal in the mold solidifies, it will form a new segment of metallic component, which will be attached to the previously solidified metal component, and is also removed from the mold. For purposes of general reference, the system shown in FIG. 1 comprises, without limitation, a liquid metal reservoir (A), a mold (1), traction means (B) and a cutting unit (C).

However, the inventive core of the invention in question relates in particular to the mold (1), which, as especially shown in FIGS. 2 and 3, comprises, in its interior, a match mold (4), being that such arrangement allows the production of a bar with hollow profile whose internal (hollow region) finish is much superior to the finish obtained from the known methods, which facilitates the machining process, when it is necessary.

Said mold (1), according to the preferred embodiment of the invention in question, comprises a molding chamber (2), provided with an outlet port (21) of metal in solid state, and a cooling channel (3) external to the molding chamber (2), provided with an inlet path (31) of cooling fluid and at least one outlet path (32) of cooling fluid.

In this context, it is noteworthy that the current state of the art already comprises molds for producing a metal component by continuous casting substantially analogous to said mold (1). Accordingly, detailed construction details relating to the molding chamber (2) and the cooling channel (3) are particularly omitted because they do not form part of the nucleus of the invention.

However, in the preferred embodiment, as shown in FIGS. 1 and 2, the molding chamber (2) is defined inside a first metal tubular body (22), and the cooling channel (3) is defined between the outer face of the already cited first metal tubular body (22) and the inner face of a second metal tubular body (23). As shown, the metal tubular bodies (22) and (23) are substantially cylindrical and concentrically aligned with respect to each other.

As particularly shown in FIG. 3, the interior of the first metal tubular body (22), i.e., the molding chamber (2) is especially adapted to receive liquid metal and allow the extraction of already solidified metal through its outlet port (21) of metal in solid state. Of course, said system has at least one closure means (D) able to hold said outlet port of metal in solid state (21) closed in the molding chamber (2) while the liquid metal changes its state to solid metal.

Also as particularly shown in FIG. 3, the space defined between the first metal tubular body (22) and the second metal tubular body (23), i.e., the cooling channel (3), is especially adapted to receive circulating cooling fluid (water at environment temperature, for example) by way of its inlet path (31) of cooling fluid and outlet path (32) of cooling fluid. Of course, said system has a fluid circulation pump (not shown) capable of continuously maintaining the flow of the circulating cooling fluid in the cooling channel (3) so that such fluid can always exchange heat with the molding chamber (2).

The mold (1) of the system for producing a metal component by continuous casting disclosed further comprises a match mold (4) disposed at least partially within the molding chamber (2).

According to the preferred embodiment of the invention in question, said match mold (4) comprises a tubular body provided with an interface end (41) and an inlet port of metal in liquid state (42), which comprises a through channel disposed at the end of the interface (41) of the match mold (4).

Considering that the inflow of liquid metal into the molding chamber (2) occurs via the inlet port (42) of the match mold (4), it is found that the interface end (41) of the match mold (4) completely obstructs the end of the molding chamber (2) opposite the metal exit port (21) in the solid state.

It will be noted, therefore, that the inlet port (42) of the match mold (4) defines a fluid communication channel between the inside and the outside of the molding chamber (2) of the system for the production of a metal component by continuous casting.

On the other side of the chamber, opposite to the entrance orifice it is a piece called “puller” D. This part is intended to block the flow of liquid metal at the very moment the first filling of the chamber occurs. After this blocking, and waiting a few seconds, the metal cools and the handle itself will play the role of the first solidified part of metal.

This technical aspect is largely different from the known state of the art, after all, in all known molds (even those, which already comprise, in one form or another, an internal match mold) the liquid metal inlet always occurs by means of an orifice in the body defining the molding chamber (2) (usually in the opening of the molding chamber (2).

Preferably, the match mold (4) is concentrically disposed within the molding chamber (2) of the mold (1) and, consequently, the general molding shape is defined by the circumferential gap existing between the molding chamber (2) and the match mold (4). Also preferably, the match mold (4) is made of graphite. It is emphasized that the match mold (4) may have the desired profile, provided it is continuous.

Preferably, but never limiting, the system comprises a liquid metal reservoir (A) in fluid communication with the inlet port of metal in liquid state (42) in the liquid state of the match mold (4). Such a reservoir may comprise any known configuration, and is not a limitation of the present invention. Considering that, also preferably, the liquid metal reservoir (A) is at an upper level, it is considered that it is adapted to insert liquid metal into the molding chamber (2), through the metal inlet port (42) in liquid state of the match mold (4), by means of gravitational force.

Preferably, but never limiting, the system also comprises a traction device (B) adapted to exert tensile force on the metal body expelled through the exit port (21) of metal in solid state of the molding chamber (2).

Also, still preferably, but never limiting, the system also comprises a traditional cutting unit (C) and not limiting of the invention.

From the “traditional” process of producing a metal component by continuous casting, provided that a system composed of a mold (1) and match mold (4), according to the invention in question, it is possible to obtain a metal component of tubular (or hollow) shape, the “external” shape of which emulates the shape of the molding chamber (2) and whose “internal” shape emulates the shape of the match mold (4).

With regard to the finishing of the metal component generated by such process, it is possible to state that the internal finish of the hollow region is much higher than the finish obtained from the known methods, which facilitates the machining process, when the same it is necessary.

Numerous variations relating to the scope of protection of the present application are permitted. Accordingly, the fact that the present invention is not limited to the particular embodiments described above is reinforced. 

1-10. (canceled)
 11. System for the production of a metal component by continuous casting, comprising: at least one mold integrated by at least one molding chamber and at least one cooling channel external to the molding chamber; said molding chamber comprising at least one outlet port of metal in solid state; said cooling channel comprising at least one inlet path of cooling fluid and at least one outlet path of cooling fluid; the system for the production of a metal component by continuous casting being especially characterized by the fact that it comprises: at least one match mold disposed at least partly inside the molding chamber of the mold; said match mold comprising a tubular body provided with at least one interface end and at least one inlet port of metal in liquid state; wherein the inlet port of metal in liquid state comprises a through channel disposed at the interface end of the match mold; wherein it further comprises at least one traction device adapted to exert tensile force on the metal body expelled through the outlet port of metal in solid state of the molding chamber; wherein said one traction device defines at least one closure means to block the flow of liquid metal at the very moment the first filling of the chamber occurs; wherein said one traction device closure means is able to hold said outlet port of metal in solid state closed in the molding chamber while the liquid metal changes its state to solid metal; and wherein said one traction device further defines a puller able to, after said blocking, play the role of the first solidified part of metal.
 12. System, according to claim 11, characterized by the fact that the interface end of the match mold completely obstructs the end of the molding chamber opposite the outlet port of metal in solid state.
 13. System, according to claim 11, characterized by the fact that the inlet port defines a fluid communication channel between the inside and the outside of the molding chamber of the system for the production of a metal component by continuous casting.
 14. System, according to claim 11, characterized by the fact that the match mold is concentrically arranged inside the molding chamber of the mold.
 15. System, according to claim 11, characterized by the fact that the general shape of the molding is defined by the circumferential gap between the molding chamber and the match mold.
 16. System, according to claim 11, characterized by the fact that the match mold is made of graphite.
 17. System, according to claim 11, characterized by the fact that it comprises a liquid metal reservoir in fluid communication with the inlet port of metal in liquid state of the match mold.
 18. System, according to claim 17, characterized by the fact that said liquid metal reservoir is adapted to insert liquid metal into the molding chamber, by means of the inlet port of metal in liquid state of the match mold by means of gravitational force. 